Imitation stucco finished metal



May 9, 1950 F. KULLMER ET AL IMITATION STUCCO FINISHED METAL Filed Dec. '19, 1945 IN VEN TORS, FRANK KULLMER.

FRED R/ENECKER.

ATTORNEY. g

Patented May 9, 1950 UNITED STATES PATENT OFFICE IMITATION STUCCO FINISHED METAL Application December 19, 1945, Serial No. 635,846

2 Claims.

This invention relates to the production of stucco like eifects, and it is especially well adapted for use with sheets or other forms of galvanized iron as a structural base.

Buildings of sheet iron are well known, but their appearance is lacking in beauty and is far from pleasing, and the heat conductivity of the metal is high.

One of the main objects of the invention is to provide a way to make such buildings (or other articles) have the pleasing appearance of stucco, while another is to lend heat-insulating qualities to the walls or other parts.

Other objects of the invention are to provide methods and materials to be used in the production of the above-mentioned objects; to provide coating materials which can be made up and stored, and which will be useful for the intended purpose immediately after being made up or after storage for any desired time; to provide a coating having the appearance of stucco and yet be very flexible so that it can be bent back and forth repeatedly without breaking, cracking, chipping or peeling; and still other objects and advantages of the invention will become apparent as this specification progresses.

The invention is illustrated on the accompanying drawings, in which similar characters of reference represent corresponding parts in the several views:

Fig. 1 is an isometric view of a piece of galvanized sheet iron.

Fig. 2 is a similar view while material which forms surface irregularities is being applied to the sheet.

Fig. 3 is a similar view after such applied material has dried and been coated with material of any desired color.

Fig. 4 is an enlarged cross section of the base and coatings thereon such as shown in Fig. 3.

A fluent composition of matter isapplied to the base material, which includes a vehicle which will dry after application and which carries granular material. The characteristics of the granular material and the vehicle are so correlated that the applied composition, after being applied and dried, will not be smooth but will have more or less closely adjacent protuberances similar to those of stucco surfaces. The best effects are obtained by using granular material which is very light in weight, that is, of light apparent specific gravity in relation to that of the vehicle, and of a special size, in combination with the vehicle.

Almost any vehicle can be used which will dry or harden within a reasonable time and which will adhere well and not run off to too great an extent, and a waterproof vehicle is preferred for outdoor use. The preferred vehicle is an aqueous bituminous emulsion, preferably containing about 55% to of asphalt, the balance being water, and a suitable small amount of emulsifying agent. The preferred emulsion contains approximately 56.5% of asphalt, 41.0% of water, and 2.5% colloid (having emulsifying properties, such, for example, as colloidal clay). Ordinary paving asphalt having the following specifications is satisfactory, but certain characteristics indicated may be varied:

Ductility at 77 F. (25 C.) About 100 cm. Penetration at 77 F About -100 Melting point About -110 F. Flash point About 485 F.

The preferred emulsion weighs about 8.4 pounds per gallon and has also the following characteristics Viscosity, Saybolt-Purol, 60 cc. at 77 F.

20 to 100 sec. Miscibility No appreciable coagulation in 2 hours Mixing Break not more than 2% Specific gravity (77 /77 F.) Not less than 1.00 Residue from distillation test (ASTM) 55% to 60% Settlement, 10 days Not more than 3% Sieve test Not more than 0.05% Demulsibility-50 ml. 0.10 N CaClz Not more than 2% Dehydration 100 F.96 hours Not less than 60% of the total mass This emulsion is dark brown in color and black when set or dried. A dried film on a backing, held in a vertical position, will not flow when subjected directly to the flame of a Bunsen burner for one minute. A coating of the emulsion dried atmospherically forty-eight hours will have a degree of ductility comparable to that of the asphalt used. Ductility and flexibility of the dried coating are important because they permit repeated bending of the sheet metal, after the coating has been applied to it, without breaking, cracking, bulging, chipping or peeling of the coating.

The granular material should have such an apparent specific gravity that it will not sink promptly to the bottom nor rise to the top of the fluid, but will remain suspended throughout the vehicle for at least a period of time suflicient to permit of easy application as a coating. Porous,

pumice-like scoria from the King Deposit in the Napa mountains of California is the material preferred for use with the vehicle described above. The major portion of such aggregate, about 80%, is granules between plus and minus mesh, that is, it will go through a 10-mesh screen but not through a .ZO-mesh screen. About 20% of total aggregate is fine dust. The scoria as mined is ground to the aforementioned sizes and is preferably calcined, this being done at about 800 to 1000 F. for about thirty minutes. The weight of the material so prepared is 37.4 lbs. per cu. ft.

The preferred. composition .-of the coating vmaterial is preferably:

5 lbs. 4 oz. of the aggregate prepared as above,

2 lbs. of the asphalt emulsion described above,

1 oz. of short fiber asbestos,

26 fluid oz. by weight of water,

0.45 gram or /3 teaspoonful of dehydrated lime,

that is, calcium oxide.

All such ingredients are well mixed together, as by means of a rotary homogenizer so that the granules are encompassed :by the asphalt. The mixture weighs about 3 lbs. per gallon and has a consistency about like that of a pancake mixture, being a pourable fluid of medium viscosity. finch composition can be applied in any suitable manner, preferabl and conveniently by spraying, for

example, by coating a sheet i I of galvanized iron by means of a spray device .92 to produce a rough wet coating l3. Good results are obtained by applying the coating in various thicknesses, As an example, excellent results are obtained when one. gallon of the coating composition is applied to 64 sq. ft. of wall surface.

The applied coating is dried atmospherically for 48 hours or longer. The resulting color is lack or almost so. The dry coating I4 is rough and adheres to the base material H and the asphaltic material surrounds and binds the granules l5. The granules l5 lend the appearance of roughness to the metal surface. A coat of paint it, which is generally prefe red to be white but it may have any desired color, is then applied to the coating.

The paint used to impart a light color should, of course, adhere to the asphaltic material, but not permit it to bleed therethrough unless the appearance, due to bleeding, is not objection.- able. To avoid bleeding, the paint should not contain amounts of mineral oil or other solvent for asphalt, and paints having a mineral .01 base are to be avoided. In other words, the outer coating should be incompatible with the first or base coating. Paints having linseed .or other drying .oil as base and those comprising resin emulsions are useful. That preferred is a cement wash, consisting of Portland cement, sand, whatever pi m nt is d sired, and water. Gener lly. the amount of sand may be about five times that of the cement, by either weight or volume, with pigment and enough Water to make a slurry which is thin enough not to make a smooth surface over the first coat. Whatever paint is applied, whether it be a cement slurry or of another nature, it should furnish an adherent coat, after drying, which hides or masks the dark color of the asphalt without forming a smooth outer surface when the rough stucco effect is desired, which is generally the case.

The above procedure may be applied to sheet iron buildings or other articles made thereof; .or it may be applied to the sheets before fabricating them into houses or other buildings or other articles. The whole coating has a high degree of adhesion and flexibility and does not chip off or peel off as a result of exposure to th weather or to salty sea water spray. Not only does the coat resist the eifects of weather and salt spray, but it also protects the underlying metal therefrom. Due to the great flexibility and excellent adhesion and ductibility of the coat, a metal sheet coated according to this invention can be bent back and forth repeatedly to a sharp angle without damage to the coating or to its adherence to the base. These characteristics of the coat are also of great advantage in permitting expansion and contraction by temperature changes without .damage to the product. Heat is conducted quick- 1y through sheet metal, and the coating lends insulating properties thereto, not only due to the insulating properties of asphalt but also to the porous, cellular structure of the scoria used, as opposed t0 a crystalline mineral.

Agreat advantage of the scoria-asphaltic emulsion composition referred to above is that, while it can be applied as soon as made up, it need not be, but can be, prepared at the plant instead of at the place of use, stored, andshipped as may be desired, and used where and when it is desired with no preparation other than precautionary stirring as a factor .of safety.

The description of th preferred form of the invention contains reference to details, some of which may be varied without departing from the spirit of the invention, the scope of which is fined in the appended Claims.

We laim-z 1. Coated sheet metal suitable for building material, comprising a base of sheet metal, a first coating on the surface of said sheet metal base comprising a bituminous coating having granular particles incorporated in said bituminous coating and covered by it and substantiall evenly dis? tributed throughout it and providing a rough appearance suggestive of stucco, and a second and outer coating hiding the dark color of the bituminous coating, the appearance of stucco being maintained, said second coating being incompatible with said first coating, said first coating being produced by applying a composition com.- prising an aqueous asphalt emulsion containing about 55 to of asphalt and having incorporated in it cellular porous scoria particles of a size capable of passing through a 10 mesh screen but not capable of passing through a 20 mesh Screen and in the ratio of about 5 lbs. .4 oz. of particles to 2 lbs. of asphalt emulsion.

2. Coated sheet metal suitable for building material, comprising a base of sheet metal, a first coating on the surface of said sheet metal base comprising a bituminous coating having particles of cellular porous granules incorporated in said bituminous coating and covered by it, substantially evenly distributed throughout it and providing a rough appearance suggestive of stucco, and a second and outer coating hiding the dark color of the bituminous coating, the appearance of stucco being maintained, said second coating being incompatible with said first coating, said first coatin being produced by applying to the sheet metal base a composition comprising the following materials in the following proportions: about 5 lbs. 4 ozs. of porous cellular scoria similar to that in the King Deposit in the Napa mountains of California, about 80% of such scoria being of a size capable of passing through a 10 mesh screen but not capable .of passing through a 20 mesh screen and about 20% being in the form 01 UNITED STATES PATENTS dust, about 2 lbs. of asphalt emulsion, about 1 oz. N of short asbestos fiber, about 26 fluid ozs. of water, gg z gg g g and about 0.45 gram of dehydrated lime, the 1906131 Root Man 1933 emulsion comprising about 56.5 parts of asphalt 5 1 g; 1936 having a melting point of about 100 F. to 110 F., 2061825 Ely Nov. 1936 and. about 41 parts of Water, and drying. 2:123:247 Lawrence et a1 July 1938 FRANK KULLMER- 2,332,311 Fadden 001;. 19, 1943 FRED RIENECKER.

REFERENCES CITED The following references are of record in the file of this patent: 

1. COATED SHEET METAL SUITABLE FOR BUILDING MATERIAL, COMPRISING A BASE OF SHEET METAL, A FIRST COATING ON THE SURFACE OF SAID SHEET METAL BASE COMPRISING A BITUMINOUS COATING HAVING GRANULAR PARTICLES INCORPORATED IN SAID BITUMINOUS COATING AND COVERED BY IT AND SUBSTANTIALLY EVENLY DISTRIBUTED THROUGHOUT IT AND PROVIDING A ROUGH APPEARANCE SUGGESTIVE OF STUCCO, AND A SECOND AND OUTER COATING HIDING THE DARK COLOR OF THE BITUMINOUS COATING THE APPEARANCE OF STUCCO BEING MAINTAINED, SAID SECOND COATING BEING INCOMPATIBLE WITH SAID FIRST COATING, SAID FIRST COATING BEING PRODUCED BY APPLYING A COMPOSITION COMPRISING AN AQUEOUS ASPHALT EMULSION CONTAINING ABOUT 55 TO 60% OF ASPHALT AND HAVING INCORPORATED IN IT CELLULAR POROUS SCORIA PARTICLES OF A SIZE CAPABLE OF PASSING THROUGH A 10 MESH SCREEN BUT NOT CAPABLE OF PASSING THROUGH A 20 MESH SCREEN AND IN THE RATIO OF ABOUT 5 LBS. 4 OZ. OF PARTICLES TO 2 LBS. OF ASPHALT EMULSION. 